Game-Changer for Future Ports: igus Equips the 2,000th Ship-to-Shore Crane with its Innovative e-chain Cable Carriers
igus e-chain systems, specifically engineered for maritime applications, significantly cuts drive energy consumption by approximately 57% compared to traditional festoons
24 March 2025 – Seaports worldwide face growing pressure to handle increasingly large vessels efficiently. To meet these demands, operators are adopting advanced Industry 4.0-compatible components, such as igus e-chain® cable carriers. igus recently marked a significant milestone by equipping its 2,000th Ship-to-Shore (STS) crane, reinforcing its role in modernizing global port infrastructure.
Maritime transport now represents over 80% of global cross-border trade, with sector growth forecasted at 2.4% annually through 2029, according to the United Nations Conference on Trade and Development (UNCTAD). This growth requires more efficient port infrastructure. Traditional festooning systems, which supply energy and data via looped cables to crane trolleys, face significant limitations.
“To handle increasing speeds and longer travel distances for larger ships, festooning systems would need motorization, which is complex and prone to error,” explained Jens Göbel, Industry Manager Cranes & Material Handling at igus. “Trolleys and festoons can lose synchronization, causing excessive tension, cable damage, and breakdowns, especially over long distances. Consequently, more port operators are transitioning to energy chain systems.”
igus e-chain systems, specifically engineered for maritime applications, operate reliably at speeds up to 10m/s without motorization. Built from durable, weather-resistant high-performance plastics, these solutions include integrated rollers to reduce friction, enabling increased payload and acceleration. This significantly cuts drive energy consumption by approximately 57% compared to traditional festoons.
These systems offer flexible cable management with easily adjustable interior separators, which is crucial in adapting to rapid technological changes. Popular models, like the heavy-duty P4HD.56.R roller energy chain, can achieve over 200,000 kilometers of operation, roughly equating to a 15-year lifespan. Specialized clevis-and-tongue connections provide stability under heavy loads, while optimized plastic pin/bore connections reduce wear.
igus e-chains also integrate seamlessly with igus iSense® sensors for real-time monitoring and predictive maintenance, significantly reducing downtime and extending crane life. igus further instills confidence by providing a four-year guarantee on these energy chain systems.
Driven by rapid technological adoption, igus has notably expanded its market share, especially in Asian ports. Since introducing its first roller energy chains at Shanghai Zhenhua Industries (ZPMC) in 2000, igus has captured approximately 60% of the market in new crane installations. After celebrating the 1,000th installation at Rotterdam’s automated APM Terminals in 2017, igus now commemorates the installation of its 2,000th STS crane, highlighting the importance of innovative solutions in port logistics.
Complementary innovations, including the igus Mobile Shore Power Outlet (iMSPO) and lubrication-free, high-load bearings, underscore igus’ ongoing commitment to sustainability and efficiency.
“We are confident these technological advancements will strengthen our collaboration with crane manufacturers and terminal operators, ultimately designing more efficient and sustainable ports for the future,” concluded Göbel.
